Construction of an arch

ABSTRACT

A frame for retaining one or more masonry slips is provided. The one or more masonry slips each have at least two slots formed on at least two sides thereof. The frame includes a supporting structure including a back plate, and is configured to house two or more masonry slips, and two or more face rails positioned on the back plate of the supporting structure. Each face rail is configured to house at least one masonry sup, and includes a projection directed away from the back plate of the supporting structure, and a retaining element positioned at the end of the projection so that the retaining element is approximately parallel to the back plate of the supporting structure, and the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a national stage entry of International ApplicationNo. PCT/EP2021/065853 filed on Jun. 11, 2021, which claims priority fromUnited Kingdom Application No. 2010776.9 filed on Jul. 13, 2020, andfrom United Kingdom Application No. 2107034.7 filed on May 17, 2021, andfrom International Application No. PCT/EP2020/069802 filed on Jul. 13,2020, the contents of each of which are incorporated by reference hereinin its entirety.

FIELD OF INVENTION

The present application is in the field of construction, andspecifically the construction of arches, and more specifically for theconstruction of arches using modern building techniques. Set out hereinare both an apparatus for forming an archway as well as a method ofassembly.

BACKGROUND

A common building construction is that of a main structure which isproduced using the latest building technology and materials, surroundedon the outside by a cladding, perhaps made of more traditional materialslike bricks. The benefits of this structure are that the main buildingcan be built from any number of new materials and therefore fulfil allbuilding regulations as these develop, while the cladding forms an outerwall that can be made more aesthetically pleasing. Such a structuretypically includes a cavity between the main building and the cladding,wherein this cavity not only increases insulation of the building fromthe external elements and environment, but also allows greaterflexibility when constructing the main building structure.

There is a particular difficulty however with certain building designsbeing constructed in this manner. Namely one such design is that of anarch construction. Arches are used in buildings to enlarge entrances,allow more light into enclosed spaces, or to mimic older style buildingdesign such as large arches used as entrances at coaching inns. There istherefore a need to be able to create such building designs through theuse of the cladding based construction. The present invention seeks toaddress these problems and provides both an apparatus for constructionof the arch as well as a method of assembly.

SUMMARY

Aspects of the invention are set out in the independent claims. Optionalfeatures are set out in the dependent claims.

According to a first aspect there is provided a frame for retaining oneor more masonry slips, the one or more masonry slips each having atleast two slots formed on at least two sides thereof, respectively, theframe comprising a supporting structure comprising a back plate, whereinthe supporting structure is configured to house two or more masonryslips, two or more face rails positioned on the back plate of thesupporting structure wherein each face rail is configured to house atleast one masonry slip, each face rail comprising a projection directedaway from the back plate of the supporting structure, and furthercomprising a retaining element positioned at the end of the projectionand such that the retaining element is approximately parallel to theback plate of the supporting structure, wherein the retaining element isconfigured to be positioned within one of the two slots formed on thesides of the masonry slip.

This has the advantage of enabling an archway to be formed using acladding type construction.

A further optional feature comprises a spacer element configured to bepositioned within a slot of a first masonry slip housed by the firstface rail, and within a slot of a second masonry slip housed by thesecond face rail, such that the spacer element maintains a set gapbetween the first masonry slip and the second masonry slip. This isparticularly advantageous as the spacer element mechanically holds themasonry slip and stops it from rotating in situ and therefore movingfrom its intended position. Such movements may be hazardous so thisgreatly improves the design.

According to a further aspect there is provided method of assembling theframe of the first aspect, the method of assembly comprising fabricatinga supporting structure comprising a back plate and at least two facerails, installing a first masonry slip into a first face rail byrotating the first masonry slip such that the first masonry slip passesvia the projection of the first face rail, installing a second masonryslip into the second face rail by rotating the second masonry slip suchthat it passes via the projection of the second face rail, wherein theslot on the side of each masonry slip is positioned level with theretaining element of the corresponding face rail parallel to the backplate, positioning the retaining elements within the corresponding sloton the side of the corresponding masonry slip.

Optionally, the method of assembly further comprising the steps ofinserting a first spacer element into the side of the masonry slip,whilst allowing enough room for the adjacent masonry slip tosubsequently be installed, and once the adjacent masonry slip isinstalled rotating the spacer element such that the spacer element is incontact with both the first and the second masonry slips, preventing themasonry slips form being rotated in the opposite direction to which theywere installed. Advantageously this may hold the masonry slipseffectively.

Optionally, wherein the spacer elements are washers, and the method ofassembly further comprising the steps of fixing the spacer elements tothe back plate, wherein the backing plate comprises pre-cut holts inlocations aligned with centres of joints between adjacent masonry slips.Advantageously this may offer a low cost solution.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 shows a supporting structure consisting of stainless-steel archlintel, back plate and underside plate with a frontal view.

FIG. 2 shows the supporting structure of FIG. 1 , from a side view.

FIG. 3 shows a frame comprising face rails and soffit rails attached tothe supporting structure of FIG. 1 , FIG. 3 shows a frontal view.

FIG. 4 shows a side view of the frame of FIG. 3 in a side view

FIG. 5 shows an enlarged perspective view of a portion of the frame ofFIG. 3 , wherein that portion is in the centre of the frame in FIG. 3 .

FIG. 6 shows a masonry slip.

FIG. 7 shows the masonry slips being rotated so that they pass via theprojecting legs of the Face Rails.

FIG. 8 shows the masonry slips in situ after being positioned within theface rails.

FIG. 9 shows the spacer element being inserted into the side of amasonry slip.

FIG. 10 shows an alternate form of spacer element being inserted in theside of the masonry slip.

FIG. 11 shows a frame with the face rail, masonry slips and spacerelements all attached.

FIG. 12 shows a frame with the face rail, masonry slips and spacerelements all attached, with a different form of spacer element shown.

FIGS. 13 and 14 show the frames of FIGS. 11 and 12 in cross section.

DETAILED DESCRIPTION

There is described herein a frame for retaining one or more masonryslips, the one or more masonry slips each having at least two slotsformed on at least two sides thereof, respectively, the frame comprisinga supporting structure comprising a back plate, wherein the supportingstructure is configured to house two or more masonry slips, two or moreface rails positioned on the back plate of the supporting structurewherein each face rail is configured to house at least one masonry slip,each face rail comprising a projection directed away from the back plateof the supporting structure, and further comprising a retaining elementpositioned at the end of the projection and such that the retainingelement is approximately parallel to the back plate of the supportingstructure, wherein the retaining element is configured to be positionedwithin one of the two slots formed on the sides of the masonry slip.This has the advantage of enabling an archway to be formed using acladding type construction.

A further optional feature comprises a spacer element configured to bepositioned within a slot of a first masonry slip housed by the firstface rail, and within a slot of a second masonry slip housed by thesecond face rail, such that the spacer element maintains a set gapbetween the first masonry slip and the second masonry slip. This isparticularly advantageous as the spacer element mechanically holds themasonry slip and stops it from rotating in situ and therefore movingfrom its intended position. Such movements may be hazardous so thisgreatly improves the design.

FIG. 1 shows an archway 10 spanning a gap between a proximal and distalend portions. The archway shown holds its own weight—moreover arches mayhave to hold both their own weight as well as the weight of some or allof an auxiliary structure positioned above the arch.

FIG. 2 shows a cross section of the arch 10 of FIG. 1 . This shows thatthe arch 10 may be formed by a supporting structure such as a fabricatedsection, or steel girder or the like functioning as a lintel. The crosssection may be hollow, or may comprise a fabricated section, or steelgirder that is not hollow.

As can be seen in the cross section whilst the cross section is broadlyrectangular there is a lip 16 at the top extending from the frontalsurface (referred to as the back plate) 12. When installed masonry slipsmay be substantially flush with the edge of this lip. Alternatively,they may extend beyond the lip. The lip is perpendicular with the backplate 12 of the supporting structure. The back plate 12 is the face ofthe arch facing outward from the building. The underside plate 14 isalso shown.

FIG. 3 shows a frame 10 comprising face rails 20 and soffit rails 30attached to the supporting structure of FIG. 1 . FIG. 3 shows a frontalview. The face rails 20 each comprise at least one projection 22directed away from the back plate 12 of the supporting structure. Theprojection 22 comprises a retaining element 24 positioned at the end ofthe projection 22 and such that the retaining element 24 isapproximately parallel to the back plate 12 of the supporting structure.In FIG. 3 the retaining elements 24 can be seen as hemispherical shapeson the face rails 20. The retaining elements 24 may be any shape. Theprojection 22 themselves are hidden by the retaining elements 24. Theprojection is perpendicular to the plan of the page in FIG. 3 and wouldpoint directly out of the page. The projection 22 provides a separationdistance between the face rail 20 and the retaining element 24 in whicha masonry slip 40 can be positioned. It is noted that in FIG. 3 eachface rail 20 comprises two projections 22 and retaining elements 24. Itis noted however than any number of projections 22 and retainingelements 24 may be used. It is also noted that multiple retainingelements 24 may emanate from a single projection 22.

FIG. 3 also shows the soffit rails 30. The soffit rails 30 are attachedto the underside plate 14. The underside plate 14 is shown as being theunderside of the arch 10. Each soffit rail 30 comprises two projections32 extending away from the underside plate 14 of the supportingstructure 10. The projections 32 in each pair are spaced apart from eachother. Each soffit rail 30 further comprises a retaining element 34extending from the end of each projection 32 such that the retainingelements 34 are substantially parallel to the underside plate 14 of thesupporting structure 10. The retaining elements 34 are attached to theprojections 32. In each pair there is a first projection 32 with anassociated retaining element 34, and a second projection 32 with anassociated retaining element 34. The first and second retaining element34 extend towards each other such that each soffit rail 30 and pair ofprojections 32 can form a slot for a masonry slip 40 such that in usethe masonry slip 40 may be held by the soffit rail 32.

FIG. 4 shows a side view of the frame of FIG. 3 in a side view. The facerail 20 on the back plate 12 of the supporting frame 10 is seen in FIG.4 . The projections 22 are perpendicular to the back plate 12. Theprojection 32 of the soffit rail 30 is also seen. The projection 32 ofthe soffit rail 30 is perpendicular to the underside plate 14 of thesupporting structure 10.

FIG. 5 shows an enlarged perspective view of a portion of the frame ofFIG. 3 , wherein that portion is in the centre of the frame 10 in FIG. 3. This shows the face rails 20, projections 22 and retaining elements 24as described above. It also shows the soffit rails 30, projections 32and retaining elements 34 as described above. It is noted that in thisexample each face rail 30 comprises projections 22 on just one side,whereas soffit rails 30 comprise projections 32 on both the left andright hand sides.

FIG. 6 shows a masonry slip 40. The masonry slip shown is in anL-shape—however many other shapes may be use. The greater length 42 ofthe masonry slip 40 may fit within a face rail 20, whilst the shorterlength 44 may fit within the soffit rail 30. Alternatively the oppositeconfiguration may be used with the greater length 42 fitting within thesoffit rail 30. Alternatively, both lengths of the masonry slip 40 maybe the same length and merely referred to as first and second lengths.They may then be used interchangeably between the face 20 and soffit 30rails. Indentations 46 are shown on both sides of the masonry slip 40.The retaining elements 24, 34 may fit within the indentations. It isnoted that the indentations on the greater length 42 of the masonry slip40 may be on only one side, however for flexibility of use it may beadvantageous for indentations 42 to be positioned on both sides asshown.

FIG. 7 shows the masonry slips 40 being rotated 50 so that they pass viathe projections 24 of the Face Rails 20. The masonry slip 40 istherefore positioned as shown such that when the indentation 46 in theside of the masonry slip 40 is level with the retaining element 24 ofthe face rail 20 parallel to the backing plate 12 this is rotated theopposite way 52 (shown in FIG. 8 ) so that the retaining element 24 sitswithin the indentation 46. It is noted that indentation and slot may beused interchangeably.

FIG. 8 shows the masonry slips 40 in situ after being positioned withinthe face rails 20. This shows that the retaining elements 24 arepositioned within the indentation 46 of the masonry slip 40.

FIG. 9 shows the spacer element 60 being inserted into the side of amasonry slip. It is essential that the masonry slips 40 are securelyfastened to the supporting structure 10. In some instances, the use ofthe face rails 20 will be enough. In other instances, the optionalsoffit rails 30 may also be used. In the embodiment shown in FIG. 9additional spacer elements 60 are being installed such that the masonryslips 40 are even more secure. Various forms of masonry slip 40 may beused. For example, those in FIG. 9 are shown as being rectangular inprofile (which includes an L-shape as shown above). In this example thespacer element 60 may comprise a clip like structure comprising acentral body portion and two arms 62 extending from either side of thebody portion, the arms 62 extending towards the centre of the bodyportion and towards each other, optionally wherein central body portionof the spacer element is substantially flat. In FIG. 9 these arepositioned between a first masonry slip and a second masonry slip.

FIG. 10 shows an alternate form of spacer element 70 being inserted inthe side of the masonry slip 40. The spacer element of FIG. 10 comprisesa washer like structure, optionally wherein the spacer element comprisesa central body with two projections. The first projection 72 emanatesfrom a proximal end of the central body upwards, and the secondprojection 74 emanates from a distal end of the central body downwards,further optionally wherein the projections are rounded and atraumatic.In this embodiment the washer is predominantly flat.

In both FIG. 9 and FIG. 10 the spacer elements are inserted into theindentation 46 of the masonry slip 40 to be installed. Duringinstallation enough space is kept for the adjacent masonry slip 40 tosubsequently be installed.

FIG. 11 shows a frame with the face rail 20, soffit rails 30, masonryslips 40 and spacer elements 60 all attached. This shows the angledspacer elements, and the retaining elements, retaining the masonry slip.The process shown in FIGS. 9 and 10 has been repeated such that allmasonry slips in the arch are installed.

After all of the masonry slips were installed the spacers 60 were thenrotated to contact the adjacent masonry slip 40 so that the spacerelements 60 prevent the masonry slips from rotating in the oppositedirection to the direction in which they were installed. Thiseffectively freezes the masonry slips 40 in place. Optional furtheradhesive may be used to cement the location of the masonry slipsfurther.

FIG. 12 shows a frame with the face rails 20, soffit rails 30, masonryslips 40, and spacer elements 70 all attached, with a different form ofspacer element shown. The washer like spacer element in shown in FIG. 12.

FIGS. 13 and 14 show the frames of FIGS. 11 and 12 in cross section.FIG. 13 shows that both the retaining element 24, 34 and the spacerelement 60 are positioned in the indentation 46 of the masonry slip 40.FIG. 14 additionally shows that for elements were washer like spacerelements 70 are used some type of further adhesive may be used to anchorthe spacer element. In FIG. 14 a self-tapping screw 80 is used to anchorthe spacer element through a pre-cut hole in the face rail (shown as acircle on the face of the face rail in many of the previous Figures).However other types of anchoring may be used as would be well known tothe person skilled in the art.

An archway may therefore be manufactured using the frame describedabove. A building incorporating such an archway and/or frame may also bemanufactured.

As is shown in the preceding Figures the arch 10 may be assembledfabricating a supporting structure comprising a back plate 12 and atleast two face rails 20. The supporting structure 10 may also compriseat least one soffit rail 30, but this is an optional feature. A firstmasonry slip 40 may be installed into a first face rail 20 by rotatingthe first masonry slip 40 such that the first masonry slip passes viathe projection 22 of the first face rail 20 (as is shown in FIG. 7 ). Asecond masonry slip 40 may then be installed by rotating the secondmasonry slip 40 such that it passes via the projection 22 of the secondface rail 20. The indentation 46 on the side of each masonry slip ispositioned level with the retaining element 24 of the corresponding facerail 20 parallel to the back plate 14. The retaining elements 24 maythen be positioned within the corresponding indentation 46 on the sideof the corresponding masonry slip.

It is noted that use of the spacer elements 60, 70 is entirely optional.If spacer elements are used they may be installed by inserting a firstspacer element 60, 70 into the side of the masonry slip, whilst allowingenough room for the adjacent masonry slip 40 to subsequently beinstalled. Once the adjacent masonry slip 40 is installed the spacerelement may be rotated such that the spacer element 60, 70 is in contactwith both the first and the second masonry slips, preventing the masonryslips from being rotated in the opposite direction to which they wereinstalled.

As noted above in relation to FIG. 14 when the spacer elements arewashers 70, a further step of assembly may include fixing the spacerelements 70 to the back plate 12, wherein the backing plate comprisespre-cut holes in locations aligned with centres of joints betweenadjacent masonry slips. The holes may alternatively be cut on the facerails 20.

As previously noted one additional optional step in fabricating thesupporting structure may comprise soffit rails 30 to the underside plate14 of the supporting structure 10.

In each of the above concepts, the material making up the elements is ofa non-flammable nature. This appropriately reduces any fire concerns inmodern buildings. Most preferably, the material for each of theseelements is stainless steel, as this does not rust and has a very highmelting point and is considered to be a safe material choice. Themasonry slips may be manufactured from an alternative material, or havea veneer of another material placed on them for aesthetic purposes.Furthermore, it will be clear that the individual elements of each ofthe options can be appropriately combined with other.

1-25. (canceled)
 26. A frame for retaining one or more masonry slips,the one or more masonry slips each having at least two slots formed onat least two sides thereof, respectively, the frame comprising: asupporting structure comprising a back plate, wherein the supportingstructure is configured to house two or more masonry slips; two or moreface rails positioned on the back plate of the supporting structure,wherein each face rail is configured to house at least one masonry slip,each face rail comprising a projection directed away from the back plateof the supporting structure, and a retaining element positioned at theend of the projection and so that the retaining element is approximatelyparallel to the back plate of the supporting structure, wherein theretaining element is configured to be positioned within one of the twoslots formed on the sides of the masonry slip.
 27. The frame of claim26, further comprising a spacer element configured to be positionedwithin a slot of a first masonry slip housed by the first face rail, andwithin a slot of a second masonry slip housed by the second face rail,so that the spacer element maintains a set gap between the first masonryslip and the second masonry slip.
 28. The frame of claim 26, wherein thesupporting structure comprises an underside plate on an underside of thesupporting structure beneath the back plate.
 29. The frame of claim 26,further comprising two or more soffit rails positioned on an undersideplate of the supporting structure, wherein each soffit rail comprisestwo projections extending away from the underside plate of thesupporting structure spaced apart from each other, each soffit railfurther comprising a retaining element extending from the end of eachprojection so that the retaining elements are substantially parallel tothe underside plate of the supporting structure, the first and secondretaining elements extending towards each other so that each can fitwithin a slot of a masonry slip so that the masonry slip is held by thesoffit rail.
 30. The frame of claim 27, wherein the spacer elementcomprises a clip like structure comprising a central body portion andtwo arms extending from either side of the body portion, the armsextending towards the centre of the body portion and towards each other,and wherein central body portion of the spacer element is substantiallyflat.
 31. The frame of claim 27, wherein the spacer element comprising awasher like structure, and wherein the spacer element comprises acentral body with two projections, and a first projection of the twoprojections emanates from a proximal end of the central body upwards,and a second projection of the two projections emanates from a distalend of the central body downwards, and wherein the projections arerounded and atraumatic.
 32. The frame of claim 26, wherein thesupporting structure is a curved supporting structure, and wherein thecurved supporting structure forms an arch.
 33. The frame of claim 27,wherein the frame comprises a second spacer element positioned betweenthe first masonry slip and the second masonry slip, and wherein thefirst spacer element is positioned above the second spacer element. 34.The frame of claim 33, wherein the first spacer element is substantiallythe same size as the second spacer element, and wherein the first spacerelement is larger than the second spacer element so that when themasonry slips are fitted the gap between the masonry slips is larger atthe top than the bottom of the join between the first and second masonryslips, and wherein the masonry slips are L-shaped.
 35. The frame ofclaim 26, the frame comprising a weight bearing support sheet; and/orwherein the frame is constructed from steel; and/or wherein thesupporting structure is a lintel structure.
 36. The frame of claim 27,wherein the spacer element either: is configured to be disposed betweena first face rail and a second face rail, or wherein the spacer elementforms part of a first face rail.
 37. The frame of claim 26, wherein eachface rail extends approximately perpendicularly away from the backplate; and/or wherein the retaining element extends approximatelyperpendicularly to the projection.
 38. An archway comprising: a framefor retaining one or more masonry slips, the one or more masonry slipseach having at least two slots formed on at least two sides thereof, theframe comprising: a supporting structure comprising a back plate,wherein the supporting structure is configured to house two or moremasonry slips; two or more face rails positioned on the back plate ofthe supporting structure, wherein each face rail is configured to houseat least one masonry slip, each face rail comprising a projectiondirected away from the back plate of the supporting structure, and aretaining element positioned at the end of the projection and so thatthe retaining element is approximately parallel to the back plate of thesupporting structure, and wherein the retaining element is configured tobe positioned within one of the two slots formed on the sides of themasonry slip.
 39. A building comprising: a frame for retaining one ormore masonry slips, the one or more masonry slips each having at leasttwo slots formed on at least two sides thereof, respectively, the framecomprising: a supporting structure comprising a back plate, wherein thesupporting structure is configured to house two or more masonry slips;two or more face rails positioned on the back plate of the supportingstructure, wherein each face rail is configured to house at least onemasonry slip, each face rail comprising a projection directed away fromthe back plate of the supporting structure, and further comprising aretaining element positioned at the end of the projection and so thatthe retaining element is approximately parallel to the back plate of thesupporting structure, and wherein the retaining element is configured tobe positioned within one of the two slots formed on the sides of themasonry slip.
 40. The building of claim 39, comprising an archway formedfrom the frame.
 41. A method of assembling the frame of claim 26, themethod of assembly comprising the steps of: fabricating a supportingstructure comprising a back plate and at least two face rails;installing a first masonry slip into a first face rail by rotating thefirst masonry slip so that the first masonry slip passes via theprojection of the first face rail; installing a second masonry slip intothe second face rail by rotating the second masonry slip so that itpasses via the projection of the second face rail; wherein the slot onthe side of each masonry slip is positioned level with the retainingelement of the corresponding face rail parallel to the back plate;positioning the retaining elements within the corresponding slot on theside of the corresponding masonry slip.
 42. The method of assembly ofclaim 41, further comprising the steps of: inserting a first spacerelement into the side of the masonry slip, while allowing enough roomfor the adjacent masonry slip to subsequently be installed; wherein oncethe adjacent masonry slip is installed rotating the spacer element sothat the spacer element is in contact with both the first and the secondmasonry slips, preventing the masonry slips form being rotated in theopposite direction to which they were installed.
 43. The method ofassembly of claim 41, wherein the spacer elements are washers, andfurther comprising the steps of: fixing the spacer elements to the backplate, wherein the backing plate comprises pre-cut holts in locationsaligned with centres of joints between adjacent masonry slips.
 44. Themethod of assembly of claim 41, further comprising fabricating anunderside plate as part of the supporting structure, and welding soffitrails to the underside plate of the supporting structure.
 45. The methodof assembly of claim 41, wherein supporting structure is curved, and/orwherein the supporting structure is a lintel, and/or wherein thesupporting structure is formed from stainless steel.